Loader with improved funnel

ABSTRACT

A horn for an automated loader is described. The horn has an interior surface, at least a portion of which comprises a reduced-friction surface. In one aspect of the invention, the reduced-friction surface comprises textures or dimples, as from textured metal, preferably textured steel. In another aspect of the invention, the reduced-friction surface comprises a coating of a slippery substance such as a thermoplastic polymer, for example polytetrafluoroethylene. In yet another aspect of the invention, the reduced-friction surface is textured metal, preferably textured steel, coated with a slippery substance such as a thermoplastic polymer, for example polytetrafluoroethylene.

PRIORITY

This application claims priority from U.S. Provisional Patent Application No. 61/624,720, filed Apr. 16, 2012, the disclosure of which is incorporated herein in its entirety.

FIELD OF THE INVENTION

The present invention relates generally to a device for loading material into a bag. The invention relates more specifically to a device for moving material into a bag where there is a high coefficient of friction between the material to be loaded and the material of the bag. The invention relates even more specifically to packaging dressed poultry in a plastic bag.

BACKGROUND OF THE INVENTION

Many types of loaders, automated and manual, are used to package material in bags. For example, the automated poultry loader described in United States Published Patent Application No. 2008/0022636 A1, Two-in-One Bagger, the disclosure of which is incorporated herein by reference, can be used to encase a whole dressed bird such as a chicken, turkey, or duck, in a plastic bag. Automated loaders of this type conventionally use horns to hold the bag open as the whole dressed bird is pushed, or rammed, into the bag. The horns either rotate in a plane to hold the bag open, as described in the '636 publication, or rotate axially, as described in, for example, U.S. Pat. No. 7,178,310, Poly-stretch Bagger System with Hocking Pusher, the disclosure of which is incorporated herein by reference. Other types of loaders, manual and automated, use a funnel system instead of horns. A schematic drawing of the funnel system as known in the prior art is shown in FIG. 1. A funnel horn 20 is a generally conically-shaped hollow tube having a wide mouth at a first end 22 and a narrow stem at a second end 24. The material to be packaged, such as a Whole dressed chicken 26, is placed at first end 22. A plastic bag 28 is opened and covers second end 24. Chicken 26 is pushed through funnel horn 20. As chicken 26 exits second end 24, it encounters the bottom of plastic bag 28. As chicken 26 continues through funnel horn 20, plastic bag 28 is pulled off funnel horn 20 and chicken 26 is completely enclosed within plastic bag 28. The bagged chicken then goes for further processing, such as clipping bag 28 and weighing and labeling the package.

In some applications, poultry such as chickens are slaughtered, defeathered, and eviscerated, and the heads and feet are removed. The carcass then is placed in a cool bath of chlorinated water to chill the bird and kill any bacteria. When the bird is ready for packaging, as described above, it is wet from the bath. In this application, the bird slides relatively easily over and through sheet metal horns and funnels, as the wet skin and the polished sheet metal have a relatively low coefficient of friction. Additionally, some degree of sliding over the plastic of the bag is achieved, as the coefficient of friction between the wet bird and the plastic is also relatively low.

in other applications, however, poultry is air dried and not subjected to a water bath. In these applications, the skin of the bird is dry. Users of these applications consider the package of a dry bird to be more pleasing to consumers than a package containing a wet bird. The drawback, however, is that there is a relatively high coefficient of friction between dry poultry skin and the stainless steel of a horn or funnel of a loader, and an even higher coefficient of friction between dry poultry skin and the plastic of a bag.

The present invention addresses sonic of the deficiencies of the prior art and presents an apparatus that can be used with both wet and dry material.

SUMMARY OF THE INVENTION

A horn for an automated loader has an interior surface, at least a portion of which comprises a reduced-friction surface. In one aspect of the invention, the reduced-friction surface comprises textures or dimples, as from textured metal, preferably textured steel. In another aspect of the invention, the reduced-friction surface comprises a coating of a slippery substance such as a thermoplastic polymer, for example polytetrafluoroethylene. In yet another aspect of the invention, the reduced-friction surface is textured metal, preferably textured steel, coated with a slippery substance such as a thermoplastic polymer, for example polytetrafluoroethylene.

A BRIEF DESCRIPTION OF THE DRAWINGS

The organization and manner of the structure and operation of the invention, together with further objects and advantages thereof, may best be understood by reference to the following description, taken in connection with the accompanying non-scale drawings, wherein like reference numerals identify like elements in which:

FIG. 1 is a schematic view of a funnel loader as used in the prior art.

FIG. 2 is a side elevation schematic view of the preferred. embodiment of the automated loader of the present invention.

FIG. 3 through 5 are side elevation schematic views of the loader of FIG. 2 shown in various stage of use.

FIG. 6 is a drawing of one type of textured steel as used in the preferred embodiment of the present invention.

FIG. 7 and 8 are drawings of other types of textured steel that can be used in the present invention.

FIG. 9 is an elevation view of a plastic bag as known in the prior art.

FIG. 10 is a perspective view of a stack of plastic bags of FIG. 9.

FIG. 11 is a side schematic view of a funnel horn of another embodiment of the present invention.

FIG. 12 is a rear elevation view of the funnel horn of FIG. 11.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

While the invention. may be susceptible to embodiment in different forms, there is shown in the drawings, and herein will be described in detail, specific embodiments with the understanding that the present disclosure is to be considered an exemplification of the principles of the invention, and is not intended to limit the invention to that as illustrated and described herein. The embodiments of the present invention will be described as part of a funnel horn or horn system to be incorporated into an automated poultry loader, for use with wet or dry poultry. The present invention can be part of a funnel horn or horn system on manual or automated poultry loaders, such as loaders for bagging and/or netting whole poultry, cut-up poultry, or whole muscle meat products. The present invention can also be used on other applications in which a material is enclosed in a casing, bag, or netting, including such materials as sealants, adhesives, and explosives, or for any other application in which a lower coefficient of friction between the material to be packaged and the funnel horn or horn system is desired.

The preferred embodiment of the automated loader of the present invention is shown in elevation schematic view in FIGS. 2 through 5. Loader 40 comprises in pertinent part a frame 42, a cylinder system 44, a bag carriage assembly 46, and a horn 48.

Horn 48 is mounted to frame 42 and is a hollow tube having an interior surface and an exterior surface. The interior surface of horn 48 defines a generally funnel shape or conical shape. Preferably, both the interior and exterior surfaces are generally funnel-shaped or conical. Horn 48 need not be in the shape of a regular horn or regular cone, but can be irregularly shaped instead.

Horn 48 has a stuffing section 50 and a stem section 54. Stuffing section 50 is at first end 52 of horn 48. Stem section 54 is at second end 56 of horn 48. Stuffing section 50 has an inlet opening at first end 52. This opening is preferably large enough at first end 52 to accommodate insertion of the material to be packaged, such as a chicken 58. Stuffing section gradually decreases in at least of inside diameter, inside width, and inside height from first end 52 to stem section 54.

Stem section 54 preferably has a relatively constant inside diameter, inside height, or inside width throughout the entire length of stem section 54 or a portion of the entire length of stem section 54, from stuffing section 50 to second end 56, that diameter, width, or height being smaller than the diameter or width of stuffing section 50 at the inlet opening at first end 52. Stem section 54 has a discharge opening at second end 56. Preferably, stem section 54 has its outside diameter, outside height, and outside width sized to accommodate the diameter of the bag 60 into which the material to be packaged, such as a chicken 58, will be stuffed, as at least a portion of stem section 54 will be inside the bag during the stuffing operation. Stem section 54 also must also have an inside diameter, inside height, and inside width configured to accommodate insertion of the material to be packaged, such as a chicken 58. it will be recognized that material to be packaged, such as a chicken 58, will fit easily into stuffing section 50 and tightly into stem section 54.

In one aspect of the present invention, at least a portion of the interior surface of horn 48 has dimples or textures. Preferably, horn 48 is formed entirely of textured or dimpled stainless steel. The inventor has fond, surprisingly, that by providing the inside of horn 48 with textures or dimples, dry chicken will slide more easily through horn 48 than it will slide through polished stainless steel, Preferably, the textured stainless steel is diamond-shaped textured stainless steel, such as HS Item Number R813000041, available from McNichols Co., Tampa, Fla., or type 4.WL, available from Mechanical Metals, Newtown, Pa. A representative diamond-shaped texture is shown schematically in FIG. 6. Other textures can be used as well, such as the ones shown, by way of example and not by way of limitation, in FIGS. 7 and 8.

Preferably, horn 48 is formed from metal having a constant wall thickness, which would provide for the stamping of textures or dimples into all of or a portion of the interior surface of the steel.

The use of a textured interior surface will ease bagging of dry poultry. Nevertheless, the apparatus can also be used with wet poultry and therefore will be more useful to users than an apparatus that can only be used with one or the other.

In another aspect of the invention, at least a portion of the interior surface of horn 48 is coated with a slippery synthetic substance, meaning a substance that has a lower coefficient of friction with the material being loaded than does smooth stainless steel and the material being loaded. Most preferably, the substance is a thermoplastic polymer, preferably polytetrafluoroethylene, most preferably one of the materials sold under the brand name Teflon® by E. I. du Pont de Nemours and Company or its affiliates. Any other slippery substance can be used as well. The use of a slippery synthetic substance will ease bagging of dry poultry. Nevertheless, the apparatus can also be used with wet poultry and therefore will be more useful to users than an apparatus that can only be used with one or the other.

In yet another aspect of the invention, the interior surface of horn 8 is made of textured or dimpled stainless steel as described above and is also coated with a slippery substance, most preferably a thermoplastic polymer, preferably polytetrafluoroethylene, most preferably one of the materials sold under the brand name Teflon® by E. I. du Pont de Nemours and Company or its affiliates, or with another slippery substance, as described above,

Plastic bag 60, as shown in elevation view in FIG. 9, has a bottom panel 62 and a top panel 64, joined at three edges by heat, ultrasonic welding, or other means. Bottom panel 62 extends slightly farther than top sheet 64 due to extended portion 66. A perforation line 68 defines the border between bottom panel 62 and extended portion 66. Plastic bag 60 is typically made of polyethylene film and may have three to ten percent ethylene vinyl acetate (EVA) as a stretch agent. Two apertures 70 are punched in extended portion 66. A stack 72 of bags 60 a, 60 b, 60 c, etc., is connected by a wicket 74, as shown in FIG. 10.

Bag carriage assembly 46 is located at a front end of frame 42. Bag carriage assembly 46 has lifting and moving mechanisms, such as air cylinders, to raise it and lower it, as is known in the art. Bag carriage assembly 46 moves from a first position, as shown in FIG. 1, to a second, raised position, as shown. in FIG. 3, to a third, inner position, as shown in FIG. 4.

An air nozzle 80 is located at the front of frame 46, just below stem section 54.

Cylinder system 44 is mounted to frame 42 opposite stuffing section 50. Cylinder system 44, as well as all other air-operated components, are connected to a pressurized air supply 82, such as a plant air system.

In use, material such as chicken 58 is placed adjacent stuffing section 50, as shown in FIG. 2. Bag carriage assembly 46 rises until top bag 60 a is adjacent stem section 54. Air nozzle 80 emits a puff of air, causing top bag 60 a to open at least partially, as shown in FIG. 3. Bag carriage assembly 46 then moves inside frame 42, causing top bag 60 a to be pulled over stem section 54, as shown in FIG. 4. Bag carriage assembly 46 moves a sufficient space that top bag 60 a is pulled completely over stem section 54 and may extend to or even partial into stuffing section 50, preferably until the bottom of top bag 60 a, encountering second end 56, prevents further movement.

Cylinder system 44 then operates to push chicken 58 through the inlet opening of stuffing section 50, and into stiffing section 50. As cylinder system 44 continues to actuate, chicken 58 continues to move through stuffing section 50 and into stem section 52. When chicken 58 encounters top bag 60 a, top bag 60 a begins to pull off horn 48 as cylinder system continues to push chicken 58 through the discharge opening of horn 48. Eventually, chicken 58 is pushed all the way through horn 48, as shown in FIG. 5, and the now-bagged chicken 58 is ready for further operations.

In another aspect of the present invention, a conventional roller conveyor 90 is mounted inside horn 48, As shown in FIGS. 11 and 12, horn 48 in this situation has the shape of an irregular cone so that the bottom is relatively flat, to accommodate roller conveyor 90. Chicken 58 will slide even more easily through horn 48 if one side of chicken 58 is resting on rollers. A horn made of plaint steel, a horn made of textured steel, a horn coated with a slippery substance, or a horn made of textured steel and coated with a slippery substance, can all be used with roller conveyor 90.

While preferred embodiments of the present invention are shown and described, it is envisioned that those skilled in the art may devise various modifications of the present invention without departing from the spirit and scope of the appended claims. 

We claim:
 1. An automated loader comprising a frame, a cylinder system, a bag carriage assembly, and a horn, the horn comprising: a hollow tube having an interior surface, a first inlet. opening, and a second discharge opening, the inlet opening being of greater inside diameter or inside width or inside height than the second discharge opening, the tube being made of stainless steel, and at least a portion of the interior surface comprising a friction-reducing surface.
 2. The automated loader of claim 1, wherein the friction-reducing surface comprises textures.
 3. The automated loader of claim 2, wherein the textures are diamond-shaped.
 4. The automated loader of claim 2, further comprising a roller tray inside the horn,
 5. The automated loader of claim 2, wherein at least a portion of the interior surface is coated with a slippery synthetic substance.
 6. The automated loader of claim 5, wherein the substance comprises a thermoplastic polymer.
 7. The automated loader of claim 6, wherein the thermoplastic polymer comprises polytetrafluoroethylene.
 8. The automated loader of claim 5, further comprising a roller tray inside the horn.
 9. The automated loader of claim 1, wherein the friction-reducing surface comprises a slippery synthetic substance.
 10. The automated loader of claim 9, wherein the substance comprises a thermoplastic polymer.
 11. The automated loader of claim 10, wherein the thermoplastic polymer comprises polytetrafluoroethylene.
 12. The automated loader of claim 5, further comprising a roller tray inside the horn.
 13. A horn for an automated loader, the horn comprising: a hollow tube having an. interior surface, a first inlet opening, and a second discharge opening, the inlet opening being of greater diameter or width than second discharge opening, the tube being made of stainless steel, at least a portion of the interior surface comprising a friction-reducing surface.
 14. The horn of claim 13, wherein the friction-reducing surface comprises textures.
 15. The horn of claim 14, Wherein the textures are diamond-shaped.
 16. The horn of claim 13, further comprising a roller tray inside the horn.
 17. The horn of claim. 14, wherein the friction-reducing surface comprises a slippery synthetic substance.
 18. The horn of claim 17, wherein the substance comprises a thermoplastic polymer.
 19. The horn of claim 18, wherein the thermoplastic polymer comprises polytetrafluoroethylene.
 20. The horn of claim 17, further comprising a roller tray inside the horn.
 21. The horn of claim 13, wherein the friction-reducing surface comprises a slippery synthetic substance.
 22. The horn of claim 21, wherein the substance comprises a thermoplastic polymer.
 23. The horn of claim 22, wherein the thermoplastic polymer comprises polytetrafluoroethylene.
 24. The horn of claim 21, further comprising a roller tray inside the horn. 